Attachment III - Technical Information

OVERVIEW

Before delivering any of the vehicles involved in this program, dealers are to retrieve DTCs and reprogram the Powertrain Control Module (PCM), Transmission Control Module (TCM), and Nitrogen Oxide (NOx) Sensor Module. If any low turbo boost or NOx sensor DTCs are retrieved, additional inspection and/or repair will be required.





REPAIR FLOWCHART

SERVICE PROCEDURE

1. Verify that the IDS is updated to version 79.01 or higher.

2. Using IDS, retrieve DTCs and check the PCM for the following Low Turbo Boost and NOx related DTCs:

^ Low Turbo Boost DTCs: P1247, P132B and/or P0299.

^ NOx DTCs: P207F, P20EE, P2200, P2201, P2209, P164A, P2A00 and/or P0133.

3. Perform the following repairs as applicable:

a. If NOx and/or Low Turbo Boost related DTCs are NOT present, proceed to "Module Reprogramming".

b. If Low Turbo Boost related DTCs are present, remove the Exhaust Downpipe following Workshop Manual (WSM), Section 309-00 and inspect the turbocharger turbine wheel for broken or missing blades.





^ Use a flashlight and inspection mirror, borescope, or other inspection tools to view the turbocharger turbine blades from the RH wheel well area (see Figure 1).

NOTE:
Figure 2, on Page 3 shows a turbine wheel with broken blades and a turbine wheel with good blades.

^ If NO DAMAGE to the turbine blades is found, the cause of Low Turbo Boost DTCs is not related to this FSA (perform normal diagnostics per PCED/WSM). Reinstall exhaust downpipe per WSM, Section 309-00 (when appropriate) and continue to step "3.c." or " Module Reprogramming" below, as applicable.

^ If DAMAGE to the turbine blades is found, replace the turbocharger per WSM, Section 303-04D.
Remove the catalyst and particulate filter assembly per WSM, Section 309-00. Remove all broken turbine blade debris from the downpipe and catalyst and particulate filter assembly by turning them vertical. Reinstall the catalyst and particulate filter assembly per WSM, Section 309-00.

^ Once repairs are complete, continue to step "3.c." or " Module Reprogramming" as applicable.

c. If NOx related DTCs are present, replace the NOx sensor per WSM, Section 303-14B. Proceed to "Module Reprogramming".

^ NOx sensor adaptive learn tables must be reset/cleared after NOx sensor replacement and module reprogramming to prevent false NOx DTCs from being set.

Module Reprogramming

Important Information For Module Programming

NOTE:
When programming or reprogramming a module, use the following basic checks to ensure programming completes without errors.

^ Make sure the battery is fully charged before carrying out the programming steps and connect IDS/scan tool to a power source.

^ Inspect Vehicle Communication Module (VCM) and cables for any damage. Make sure scan tool connections are not interrupted during programming.

^ A hardwired internet connection is strongly recommended.

^ Turn off all unnecessary accessories (radio, heated/cooled seats, headlamps, interior lamps, HVAC system, etc.), close doors.

^ Disconnect/depower any aftermarket accessories (remote start, alarm, power inverter, CB radio, etc.).

^ Follow all scan tool on-screen instructions carefully.

^ Disable IDS/scan tool sleep mode, screensaver, hibernation modes.

^ Create all sessions Key On Engine Off (KOEO). Starting the vehicle before creating a session will cause errors within the programming inhale process.

NOTE:
Reprogram appropriate vehicle modules before performing diagnostics and clear all DTCs after programming. For DTCs generated after reprogramming, follow normal diagnostic service procedures.

1. Reprogram the PCM, TCM (if prompted), and NOx Sensor Module to the latest calibration using IDS release 79.01 or higher. When reprogramming the PCM, the NOx Module will be automatically reprogrammed to the latest level. Calibration files may be obtained at the website.

2. If the NOx sensor was replaced, reset/clear the NOx sensor adaptive learn tables. This will prevent false NOx DTCs from being set. Resetting/clearing of the NOx adaptive learn tables can be accomplished with IDS. To reset/clear the NOx adaptive learn tables:

a. From the IDS main menu, click the "Toolbox" icon.

b. Select "Powertrain"

c. Select "Service Functions"

d. Select "Reset/Clear Specified Function" and select "Yes" when prompted.

e. Select "Nitrogen Oxide"

NOTE:
For vehicles equipped with an automatic transmission, advise the customer that this vehicle is equipped with an adaptive transmission shift strategy which allows the vehicle's computer to learn the transmission's unique parameters and improve shift quality. When the adaptive strategy is reset, the computer will begin a re-learning process. This re-learning process may result in firmer than normal upshifts and downshifts for several days.

Recovering a PCM/Body Control Module (BCM) when programming has resulted in a blank module: NEVER DELETE THE ORIGINAL SESSION!

1. Obtain the original IDS that was used when the programming error occurred during Module
Reprogramming (MR) or Programmable Module Installation (PMI).

2. Disconnect the VCM from the data link connector (DLC) and the IDS.

3. Reconnect the VCM to IDS and then connect to the DLC. Once reconnected, the VCM icon should appear in the corner of the IDS screen. If it does not, troubleshoot the IDS to VCM connection.

4. Locate the ORIGINAL vehicle session when programming failed. This should be the last session used in most cases. If not, use the session created on the date that the programming failed.

NOTE:
If the original session is not listed in the previous session list, click the ''Recycle bin'' icon at the lower right of the previous session screen. This will load any deleted sessions and allow you to look through them. Double-click the session to restore it.

5. Once the session is loaded, the failed process should resume automatically.

6. If programming does not resume automatically, proceed to the Module Programming menu and select the previously attempted process, Programmable Module Installation (PMI) or Module Reprogramming.

7. Follow all on-screen prompts/instructions.

8. Near the end of programming, the IDS will prompt you to select certain parameters. It is important to make a selection for ALL parameters listed. If the correct selection is already highlighted, you must still choose that selection before clicking the "Tick" mark to complete the configuration.

9. The last screen on the IDS may list additional steps required to complete the programming process.
Make sure all applicable steps listed on the screen are followed in order.